Engine air management system

ABSTRACT

An engine air management system is provided for an internal combustion engine generating blowby gas in a crankcase containing engine oil and oil aerosol. The system includes combinations of two or more of an air-oil separator, an air filter, and an acoustic silencer.

BACKGROUND AND SUMMARY

The invention relates to engine air management systems for internalcombustion engines.

Internal combustion engines take in large amounts of air and alsogenerate a relatively small amount of blowby gas in the crankcasecontaining engine oil and oil aerosol. The air management system mayinclude an air intake filter as well as an air-oil separator having aninlet receiving blowby gas and oil aerosol from the crankcase, an airoutlet discharging clean blowby gas, and an oil outlet dischargingscavenged separated oil.

The present invention arose during continuing development efforts in theabove technology.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an engine air management system inaccordance with the invention.

FIG. 2 is like FIG. 1 and shows another embodiment.

FIG. 3 schematically illustrates a further embodiment.

FIG. 4 is like FIG. 3 and shows another embodiment.

FIG. 5 is like FIG. 4 and shows another embodiment.

FIG. 6 schematically illustrates a further embodiment.

FIG. 7 is like FIG. 6 and shows another embodiment.

FIG. 8 schematically illustrates a further embodiment.

FIG. 9 is a perspective view of a further embodiment.

FIG. 10 is a partially exploded view of the assembly of FIG. 9.

DETAILED DESCRIPTION

FIG. 1 shows an engine air management system 10 for an internalcombustion engine 12 generating blowby gas in a crankcase 14 containingengine oil and oil aerosol. In the embodiment of FIG. 1, the systemincludes a combined crankcase ventilation filter and air cleaner 16. Thesystem includes an air-oil separator 18 having an inlet 20 receivingblowby gas and oil aerosol as shown at arrow 22 from crankcase 14, andhaving an air outlet 24 discharging clean blowby gas as shown at arrow26, and having an oil outlet 28 discharging scavenged separated oil asshown at arrow 30 back to crankcase 14. The system further includes acombustion air intake 32 supplying combustion air to engine 12 as shownat arrow 34, to air intake manifold 36, or to a turbocharger orsupercharger, etc. The combustion air intake includes an air filter 38supplying clean combustion air to the engine as shown at arrow 34. Airfilter 38 is a standard air filter and receives incoming ambient air atinlet 40 as shown at arrow 42, which air is then filtered by flowingradially inwardly through annular air filter element 44 as shown atarrows 46, which air flows into hollow interior 48 of the annular filterelement 44, and then flows axially as shown at 50 to outlet 52 to supplythe noted combustion air as shown at arrow 34. Air-oil separator 18 isprovided by an annular coalescing filter media element 54 through whichthe blowby gas and oil aerosol flow radially inwardly as shown at arrow56 into hollow interior 58 and then the clean blowby gas 26 turns andflows axially through outlet 24 and joins the cleaned combustion air inhollow interior 48 of air filter element 44 to flow axially as shown at50 through outlet 52 and then to the engine as shown at arrow 34. In thepreferred embodiment, air-oil separator 18 is a coalescer. In anotherembodiment, the air-oil separator of the crankcase ventilation filter isan impactor separator. As is known, air filters such as 38 may include apurge outlet such as 39, which may include a purge valve, fordischarging debris or particulate. The embodiment in FIG. 1 is a closedcrankcase ventilation (CCV) system, wherein the clean blowby gas 26 isreturned to the engine. In other embodiments, to be described, an opencrankcase ventilation (OCV) system is provided, wherein the clean blowbygas is vented to atmosphere. In a CCV system as in FIG. 1, it ispreferred that a crankcase depression regulator (CDR) 23 be provided,either in the blowby gas and oil aerosol conduit at 22, or in thecombustion air conduit at 34, as is known.

In the preferred embodiment, air outlet 24 of air-oil separator 18supplies clean blowby gas to the combustion air intake 32 as shown atarrows 26, 50, 34. Combustion air flows from upstream to downstreamthrough the combustion air intake, including through the air filter, tothe engine, as shown at arrows 42, 46, 50, 34. In FIG. 1, air outlet 24of air-oil separator 18 supplies clean blowby gas to the combustion airintake downstream of air filter element 44 of air filter 38.

The combined crankcase ventilation filter and air cleaner is housed in ahousing 60 having a plurality of ports 40, 20, 52, 28, 24, and first andsecond chambers 62 and 64. Chamber 62 contains air filter element 44 ofthe air filter. Combustion air flows from upstream to downstream throughport 40 then through air filter element 44 in chamber 62 then throughport 52 to the engine. Chamber 64 contains the air-oil separator. Blowbygas and oil aerosol flow through port 20 to the air-oil separator inchamber 64. The housing extends axially along axis 66. First and secondchambers 62 and 64 are axially aligned in housing 60 in axially stackedend-to-end relation. Housing 60 has an axially extending outer wall 68,and a dividing wall 70 extending radially inwardly from outer wall 68between first and second chambers 62 and 64 and axially separatingchambers 62 and 64. Port 40 of the housing is on a first axial side ofdividing wall 70, e.g. the right side 72 in the orientation of FIG. 1.Port 20 of the housing is on a second axial side of dividing wall 70,e.g. the left side 74 in the orientation of FIG. 1. Left side 74 ofdividing wall 70 faces axially distally oppositely from right side 72 ofdividing wall 70. Port 52 of the housing is on the noted right axialside 72 of dividing wall 70. Housing 60 has a fourth port as shown at28, which fourth port is in second chamber 64 on the noted left side 74of dividing wall 70 and drains scavenged separated oil as shown at arrow30. Housing 60 has a fifth port 24, which may be an internal transferport as shown in FIG. 1, or may be an external port as shown in FIG. 2to be described, which fifth port 24 is in the noted second chamber 64and discharges clean blowby gas as shown at arrow 26. In the embodimentof FIG. 1, fifth port 24 is formed through dividing wall 70 anddischarges clean blowby gas axially therethrough from second chamber 64to first chamber 62.

In FIG. 1, air filter element 44 of the air cleaner filter is an annulushaving the noted hollow interior 48 and extends axially along axis 66 infirst chamber 62. Combustion air flows radially inwardly as shown atarrows 46 through the annulus into hollow interior 48 and then axiallyas shown at arrow 50 through the noted third port 52. The noted fifthport 24 extends axially through dividing wall 70. Clean blowby gas flowsas shown at arrow 26 from second chamber 64 axially through fifth port24 into first chamber 62 and joins combustion air in hollow interior 48of the annulus as shown at arrow 76.

Annular air filter element 44 extends axially in chamber 62 betweenfirst and second distally opposite axial ends 78 and 80. The noted thirdport 52 is at first axial end 78 of the annulus. Air-oil separator 18 isat the second axial end 80 of the annulus and axially spaced therefromby dividing wall 70 therebetween. Second axial end 80 of the annulusaxially faces the noted first side 72 of the dividing wall 70. Air-oilseparator 18 at coalescer element 54 axially faces the noted second side74 of dividing wall 70. In the preferred embodiment, as noted, theair-oil separator is a coalescer 54 in second chamber 64, and fifth port24 is the noted air outlet of the air-oil separator, and fourth port 28is the noted oil outlet of the air-oil separator.

FIG. 2 is like FIG. 1 and uses like reference numerals from above whereappropriate to facilitate understanding. Dividing wall 70 of FIG. 1 isreplaced in FIG. 2 by dividing wall 82 which isolates second chamber 64from first chamber 62. Dividing wall 82 is a solid wall, without acentral opening at 24 otherwise providing the noted fifth port. Instead,a fifth port 84 is provided from second chamber 64 and extendsexternally of housing 60 and discharges clean blowby gas externally ofthe housing as shown at arrow 86, which clean blowby gas may bedischarged to atmosphere as shown in FIG. 2 (OCV-open crankcaseventilation), or may be returned to the engine (CCV-closed crankcaseventilation), e.g. at air intake manifold 36, separately from combustionair 34, or may be combined therewith and then supplied to air intakemanifold 36.

FIG. 3 shows a further embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. The combustion airintake includes a duct 90 directing combustion air 42 from upstream todownstream axially therealong, leftwardly in FIG. 3. A primary airfilter element is shown at 92, and a safety or secondary air filterelement is shown at 94. The air-oil separator is provided by an annularcoalescer filter element 96 having a hollow interior 98 extendingaxially in the duct. Blowby gas 22 flows radially inwardly throughannular coalescer filter 96 and joins the combustion air in hollowinterior 98 and then flows axially as shown at 50, to be supplied to airintake manifold 36. Oil outlet 28 is downstream of air filter 92, 94.Blowby gas joins combustion air downstream of air filter 92, 94.

FIG. 4 is like FIG. 3 and uses like reference numerals from above whereappropriate to facilitate understanding. Coalescer filter element 96 ofFIG. 3 is replaced by coalescer filter element 100 of FIG. 4 where aninside-out flow is desired for the coalescer.

FIG. 5 is like FIG. 4 and uses like reference numerals from above whereappropriate to facilitate understanding. Blowby gas 22, after passingthrough coalescer filter element 101, joins the combustion air upstreamof the air filter. In the embodiments of FIGS. 3-5, the combustion airintake extends through the air-oil separator.

FIG. 6 shows a further embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. Clean blowby gas 26from air-oil separator 18 joins combustion air upstream of air filter38. This provides a CCV system.

FIG. 7 is like FIG. 6 and uses like reference numerals from above whereappropriate to facilitate understanding. Port 24 in FIG. 6 is replacedby solid dividing wall 82 in FIG. 7 such that clean blowby gas 26 isinstead vented to atmosphere through port 84. This provides an OCVsystem. In an alternative, the clean blowby gas 26 in FIG. 7 may bereturned to the engine, e.g. at air intake manifold 36, separately fromcombustion air 34 or may be combined therewith and then supplied to airintake manifold 36, to provide a CCV system.

FIG. 8 shows a further embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. Engine intake airmanagement system 110 is provided for internal combustion engine 12 asabove, which engine generates blowby gas in a crankcase 14 containingengine oil and oil aerosol. The system includes a combined crankcaseventilation filter and acoustic silencer 112. The crankcase ventilationfilter includes an air-oil separator 114 which has an inlet 116receiving blowby gas and oil aerosol 22 from crankcase 14, and has anair outlet 118 discharging clean blowby gas as shown at arrow 26, andhas an oil outlet 122 discharging scavenged separated oil as shown atarrow 30. The system further includes a combustion air intake 32supplying combustion air to the engine as shown at 34. An upstream airfilter may be provided as shown at 122, or may be provided as shownabove. The combustion air intake includes an acoustic silencer 124providing acoustic silencing of engine noise in the combustion airintake as schematically shown at engine noise sound waves 126 travelingback up the combustion air intake in the orientation of FIG. 8. Thecombustion air intake is provided by a duct 128 extending throughair-oil separator 114 and through acoustic silencer 124. Air-oilseparator 114 and acoustic silencer 124 each concentrically surroundduct 128. In the preferred embodiment, air-oil separator 114 is acoalescer and is provided by combined coalescing and acousticalabsorption media 130. Further in the preferred embodiment, a liner 132is provided between the combustion air intake 32 at duct 128 and media130. Liner 132 is an annular cylindrical sleeve and preferably is all ofthe following: a) acoustically permeable; b) gas permeable; and c) atleast partially liquid impermeable. Combustion air intake 32 ispreferably provided by a perforated duct 128 having perforations 134communicating with media 130 such that blowby gas flows in a firstdirection 136 through perforations 134, and acoustic sound waves travelin a second opposite direction 138 through perforations 134. Media 130and duct 128 at perforations 134 are separated by an interface gap 140.Liner 132 extends along interface gap 140.

In a further preferred embodiment, duct 128 extends axially along axis142 at least partially vertically to have a lower portion 144gravitationally below an upper portion 146. Upper portion 146 has thenoted perforations 134. Lower portion 144 is unperforated and blocks theflow of scavenged separated oil from the air-oil separator from enteringcombustion air intake 32. Media 130 is an annulus extending axiallyalong axis 142 and has a circumferential inner face 148 facing radiallyinwardly toward duct 128, and has a circumferential outer face 150facing radially outwardly. A housing 152 concentrically surrounds theannulus of media 130 and has the noted inlet 116 receiving blowby gasand oil aerosol at 22 from crankcase 14. Housing 152 has an axiallyextending sidewall 154 spaced radially outwardly of outer face 150 ofannular media 130 by an annular pressure equalization plenum 156 aroundthe outside of media 130 facilitating uniform flow of blowby gas throughthe media.

FIGS. 9 and 10 show a further embodiment and use like reference numeralsfrom above where appropriate to facilitate understanding. Engine intakeair management system 170 is provided for internal combustion engine 12as above, which engine generates blowby gas in a crankcase 14 containingengine oil and oil aerosol. The system includes a combined crankcaseventilation filter and air cleaner at housing 172. The system includesan air-oil separator 174 having an inlet 176 receiving blowby gas andoil aerosol as shown at arrow 22 from crankcase 14, and having an airoutlet 178 discharging clean blowby gas as shown at arrow 26, and havingan oil outlet 180 discharging scavenged separated oil as shown at arrow30 back to crankcase 14. The system further includes a combustion airintake as above supplying combustion air to engine 12 as shown at arrow34 to air intake manifold 36, or to a turbocharger or supercharger, etc.The combustion air intake includes an air filter 182 including an airfilter element 184 receiving incoming ambient air at inlet 186 as shownat arrow 42, which air is then filtered by flowing axially leftwardlyalong axis 188 through air filter element 184 and then to outlet 190 asshown at outlet arrow 34. Air-oil separator 174 is preferably providedby coalescing filter media element 192.

Housing 172, FIGS. 9, 10, has first, second, third, fourth and fifthports 186, 176, 190, 180, 178, respectively. First and second ports 186and 176 are inlet ports. Third, fourth and fifth ports 190, 180 and 178are outlet ports. Housing 172 has first and second chambers 194 and 196.First chamber 194 contains air filter element 184. Second chamber 196contains coalescer filter element 192. Combustion air flows fromupstream to downstream through port 186 as shown at arrow 42 thenthrough the air filter in first chamber 194 then through port 190 asshown at arrow 34 to engine 12. Blowby gas and oil aerosol flow as shownat arrow 22 through port 176 to the air-oil separator provided bycoalescer filter element 192 in chamber 196. Clean blowby gas flowsthrough outlet port 178 as shown at arrow 26 and may be vented toatmosphere (OCV) or may be returned to the engine (CCV). Scavengedseparated oil is discharged at drain port 180 as shown arrow 30 forreturn to crankcase 14.

Housing 172 extends axially along axis 188. First and second chambers194 and 196 extend axially and are laterally aligned in side-by-siderelation. The housing has an axially extending dividing wall 198laterally between and separating and isolating first and second chambers194 and 196. In the embodiment in FIGS. 9 and 10, the air filter is aflat panel air filter having an axial length along axial direction 200along axis 188, a lateral width along a lateral direction 202, and atransverse height along a transverse direction 204. The noted height isless than each of the noted length and width. Second chamber 196 islaterally adjacent first chamber 194 along the noted lateral direction202 on the opposite lateral side of dividing wall 198. First and thirdports 186 and 190 are in first chamber 194. Second, fourth and fifthports 176, 180 and 178 are in second chamber 196.

Housing 172 extends axially along the noted axial direction 200 betweendistally opposite first and second axial ends 206 and 208. The notedfirst and second ports 186 and 176 are at first axial end 206. The notedthird and fifth ports 190 and 178 are at second axial end 208. Flatpanel air filter element 184 has an axial end 210 at the noted firstaxial end of the housing. Coalescer filter element 192 has an axial end212 at the noted first axial end of the housing. The first axial end ofthe housing is preferably provided by one or more end caps 214 removablefrom the housing, e.g. at clamps such as 216, to provide service accessto flat panel air filter element 184 and coalescer filter element 192 atthe noted respective axial ends thereof 210 and 212. The noted one ormore end caps 214 may be provided by a single unitary end cap as shown,or may be split into two end caps, one for air filter element 184, andthe other for coalescer filter element 192. First and second ports 186and 176 extend through the noted one or more end caps. Various types ofair filter elements and coalescer filter elements may be used, forexample an air filter element in accordance with U.S. Pat. Nos.6,375,700 and 7,314,558, and a coalescer filter element in accordancewith U.S. patent application Ser. Nos. 11/940,626, 11/940,729,12/026,720, all incorporated herein by reference.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beinferred therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued. The different configurations, systems, and method stepsdescribed herein may be used alone or in combination with otherconfigurations, systems and method steps. It is to be expected thatvarious equivalents, alternatives and modifications are possible withinthe scope of the appended claims. Annular includes cylindrical,elliptical, oval, racetrack, and other closed-loop shapes.

What is claimed is:
 1. An engine air management system for an internal combustion engine generating blowby gas in a crankcase containing engine oil and oil aerosol, said system comprising a combined crankcase ventilation filter and air cleaner comprising an air-oil separator having an inlet receiving blowby gas and oil aerosol from said crankcase, and having an air outlet discharging clean blowby gas, and an oil outlet discharging scavenged separated oil, said system further comprising a combustion air intake supplying combustion air to said engine, said combustion air intake including an air filter supplying clean combustion air to said engine, and comprising a housing having first, second, third, fourth and fifth ports, wherein: said first and second ports are inlet ports; said third port is an outlet port; said housing has first and second chambers; said first chamber contains an air filter; combustion air flows from upstream to downstream through said first port then through said air filter in said first chamber then through said third port to said engine; said second chamber contains said air-oil separator; said blowby as and oil aerosol flow through said second port to said air-oil separator in said second chamber; said fourth port is in said second chamber and drains said scavenged separated oil; said fifth port is in said second chamber and discharges said clean blowby gas, wherein: said housing extends axially along an axis defining an axial flow direction; said first and second chambers extend axially and are laterally aligned in side-by-side relation; said housing has an axially extending dividing wall laterally between and separating and isolating said first and second chambers; said air filter is a flat panel filter having an axial length along an axial direction, a lateral width along a lateral direction, and a transverse height along a transverse direction; said height is less than each of said length and said width; said second chamber is laterally adjacent said first chamber along said lateral direction and on the opposite lateral side of said dividing wall, wherein said combustion air from said first port flows in said axial flow direction through said first chamber along a first axial flow path, said blowby gas and oil aerosol from said second port flows in said axial flow direction through said second chamber along a second axial flow path, and said first and second axial flow paths are separate from and laterally spaced from each other.
 2. The engine air management system according to claim 1 wherein: said housing extends axially along said axial direction between distally opposite first and second axial ends; said first and second ports are at said first axial end; said third and fifth ports are at said second axial end.
 3. The engine air management system according to claim 1 wherein: said housing extends axially along said axial direction between distally opposite first and second axial ends; said air-oil separator comprises a coalescer filter in said second chamber; said flat panel air filter has an axial end at said first axial end of said housing; said coalescer filter has an axial end at said first axial end of said housing; said first axial end of said housing comprises one or more end caps removable from said housing to provide service access to said flat panel air filter and said coalescer filter at said respective axial ends thereof.
 4. An engine air management system for an internal combustion engine generating blowby gas in a crankcase containing engine oil and oil aerosol, said system comprising a combined crankcase ventilation filter and air cleaner comprising an air-oil separator having an inlet receiving blowby gas and oil aerosol from said crankcase, and having an air outlet discharging clean blowby gas, and an oil outlet discharging scavenged separated oil, said system further comprising a combustion air intake supplying combustion air to said engine, said combustion air intake including an air filter supplying clean combustion air to said engine, and comprising a housing having first, second, third, fourth and fifth ports, wherein: said first and second ports are inlet ports; said third port is an outlet port; said housing has first and second chambers; said first chamber contains an air filter; combustion air flows from upstream to downstream through said first port then through said air filter in said first chamber then through said third port to said engine; said second chamber contains said air-oil separator; said blowby gas and oil aerosol flow through said second port to said air-oil separator in said second chamber; said fourth port is in said second chamber and drains said scavenged separated oil; said fifth port is in said second chamber and discharges said clean blowby gas, wherein: said housing extends axially along an axis; said first and second chambers extend axially and are laterally aligned in side-by-side relation; said housing has an axially extending dividing wall laterally between and separating and isolating said first and second chambers; said air filter is a flat panel filter having an axial length along an axial direction, a lateral width along a lateral direction, and a transverse height along a transverse direction; said height is less than each of said length and said width; said second chamber is laterally adjacent said first chamber along said lateral direction and on the opposite lateral side of said dividing wall; said housing extends axially along said axial direction between distally opposite first and second axial ends; said air-oil separator comprises a coalescer filter in said second chamber; said flat panel air filter has an axial end at said first axial end of said housing; said coalescer filter has an axial end at said first axial end of said housing; said first axial end of said housing comprises one or more end caps removable from said housing to provide service access to said flat panel air filter and said coalescer filter at said respective axial ends thereof, wherein said first and second ports extend through said one or more end caps. 